Waterproof USB drives and method of making

Abstract

A data storage device and methods of manufacture are provided which tend to protect the device against moisture and shock. The device includes a circuit board, a coating, a housing, and preferably a sealant. The circuit board is in electrical communication with an electrical interface. The coating is disposed at least on the circuit board to generally encapsulate the circuit board. The housing is sized and configured to generally encompass the circuit board and the coating. The housing includes a housing opening being sized and configured with the electrical interface being at least partially exposed therethrough. The sealant is preferably disposed within the housing substantially intermediate the interior surface of the housing and the coating on the circuit board. Further, at least one of the coating and the sealant may be disposed substantially intermediate the electrical interface and the housing opening.

1. A data storage device protected against moisture and shock, the device comprising:
 an electrical interface defining opposing end portions, the electrical interface being electrically and mechanically connectable to an external electrical device; 
 a circuit board being in electrical communication with the electrical interface; 
 a fluid tight coating being disposed on the circuit board and at least one of the opposing end portions of the electrical interface; 
 a housing having a housing interior, the housing interior being sized and configured to generally encompass the circuit board and the coating, the housing defining an interior surface and including a housing opening, the housing opening being sized and configured with the electrical interface being at least partially exposed therethrough; and 
 an expandable fluid tight sealant being disposed within the housing interior substantially intermediate the interior surface of the housing and the coating on the circuit board and expandable to vent air out of the housing interior through the housing opening to remove air gaps within the housing interior, and provide a fluid tight seal within the housing interior, the sealant further being disposed about the electrical interface to provide a fluid tight seal between the electrical interface and the housing opening, and the sealant also provides adhesion between the circuit board and the housing. 
 
   
   
     2. The device of  claim 1  wherein the fluid tight coating generally encapsulates the circuit board. 
   
   
     3. The device of  claim 1  wherein the fluid tight coating is conformal to the circuit board. 
   
   
     4. The device of  claim 1  wherein the fluid tight coating is free of voids. 
   
   
     5. The device of  claim 1  wherein the fluid tight coating is a polymeric resin. 
   
   
     6. The device of  claim 1  wherein the fluid tight coating is a polyimide resin. 
   
   
     7. The device of  claim 1  wherein the fluid tight sealant is expandable foam. 
   
   
     8. The device of  claim 1  wherein the fluid tight sealant is a thermoplastic foam sealant. 
   
   
     9. The device of  claim 1  wherein the fluid tight sealant is adhesive paste containing microporous polymer fillers. 
   
   
     10. The device of  claim 1  wherein the fluid tight sealant substantially conforms to the interior surface of the housing. 
   
   
     11. The device of  claim 1  wherein the housing includes upper and lower halves being cooperatively engageable to form the housing and create a seam therebetween, the seam between the upper and lower halves of the housing being hermetically sealed. 
   
   
     12. A data storage device protected against moisture and shock, the device comprising:
 an electrical interface being electrically and mechanically connectable to an external electronic device; 
 a circuit board being in electrical communication with the electrical interface and having a fluid tight coating disposed thereon; 
 a housing being sized and configured to generally encompass the circuit board, the housing defining an interior surface and including a housing opening, the housing opening being sized and configured with the electrical interface being at least partially exposed there through, the housing includes upper and lower halves being cooperatively engageable to form the housing and create a seam therebetween, the seam between the upper and lower halves of the housing being hermetically sealed and an expandable fluid tight sealant being disposed within the housing substantially intermediate the interior surface of the housing and the circuit board coating and substantially intermediate the electrical interface and the housing opening, and the sealant also provides adhesion between the circuit board and the housing. 
 
   
   
     13. The device of  claim 1  wherein the electrical interface is a USB connector. 
   
   
     14. The device of  claim 1  wherein the electrical interface is electrically and mechanically connectable to a USB compatible external electrical device. 
   
   
     15. The device of  claim 1  wherein the electrical interface is abuttingly connectable with the external electrical device. 
   
   
     16. The device of  claim 1  wherein the circuit board is configured to store data. 
   
   
     17. A data storage device comprising:
 a housing having a housing interior, the housing defining an interior surface and a housing opening; 
 a circuit board disposed within the housing interior and having a fluid tight coating disposed thereon; 
 an electrical interface in electrical communication with the circuit board, the electrical interface being electrically and mechanically connectable to an external electronic device, the electrical interface being at least partially disposed within the housing opening; 
 a fluid tight protective layer disposed at least on the circuit board and about the electrical interface to provide a fluid tight seal between the housing opening and the electrical interface; and 
 an expandable fluid tight sealant disposed within the housing interior substantially intermediate the interior surface of the housing and the coating on the circuit board and expandable to vent air out of the housing interior through the housing opening to remove air gaps within the housing interior and provide a fluid tight seal within the housing interior, the sealant further being disposed about the electrical interface to provide a fluid tight seal between the electrical interface and the housing opening, and the sealant also provides adhesion between the circuit board and the housing. 
 
   
   
     18. The data storage device of  claim 17  wherein the fluid tight protective layer is disposed within the housing substantially intermediate the interior surface of the housing and the circuit board. 
   
   
     19. The data storage device of  claim 17  wherein the fluid tight coating generally encapsulates the circuit board. 
   
   
     20. The data storage device of  claim 1  wherein the coating being operative to activate at room temperature. 
   
   
     21. The data storage device of  claim 1 , wherein the sealant being disposed within the housing interior and expandable to provide a fluid tight seal that stabilizes that electrical interface within the housing opening. 
   
   
     22. The device of  claim 11  wherein the upper half is pivotable relative to the lower half between a closed position and an open position, the housing to receive the expandable fluid tight sealant when the upper half is disposed in the open position.